Releasable, repeatable electrical connection employing compression

ABSTRACT

An electrical connection of a transfer station releasably, repeatably electrically couples with respect to a matching connection of a portable cartridge. A substrate in the portable cartridge has electrical contacts on a facing surface. In the transfer station, a matching circuitized flexible substrate has electrical contacts on a facing surface thereof, which are arranged to match the portable cartridge electrical contacts when in a face-to-face relationship. An elastomeric compression element, at the rear of the matching substrate, has individual protruding compression members contacting the rear surface and registered with corresponding individual electrical contacts. Elongated electrical contacts are registered with two adjacent individual compression members. A loader engages the portable cartridge, registering the cartridge substrate contacts in face-to-face relation with the matching flexible substrate electrical contacts, and exerting a normal force to the cartridge to compress the compression element and create non-wiping contact between the facing electrical contacts.

CROSS REFERENCE TO RELATED APPLICATION

[0001] Copending and coassigned U.S. Patent Application Ser. No.(TUC920010002) filed on even date herewith relates to alternative mediadevices mounted in portable data storage type cartridges, and a transferstation for providing data transfer with respect to such portable datastorage cartridges.

TECHNICAL FIELD OF THE INVENTION

[0002] This invention relates to electrical interconnection apparatus,and, more particularly, to electrical interconnection apparatus for thetransfer of data to and from a portable agent, and for the transfer oflow voltage power.

BACKGROUND OF THE INVENTION

[0003] Data storage cartridges typically comprise a data storage media,such as magnetic tape, which are inserted into a separate data storagedrive so that data may be read and/or written on the data storage media.Such cartridges are convenient means of storing large quantities of datawhich are accessed occasionally. They are particularly useful inautomated data storage libraries which can contain large numbers of thecartridges on storage shelves and employ a robot accessor to access acartridge when needed and deliver the cartridge to a data storage drive.

[0004] The typical portable cartridge presently employs a data storagemedia, such as a length of magnetic tape, which must be open or openablewhen inserted in a fixed data storage drive to allow the data storagedrive to read and/or write data on the media.

[0005] An inhibitor to the use of any direct data transfer to portablecartridges, instead of to the media which is stored in the cartridge,has been the problem of the interconnection. Detachable data storagedevices are known, for example, in U.S. Pat. No. Re. 34,369, or JapanesePatent 7-220464, which employ pluggable connectors. Pluggable connectorstypically employ pins and receptacles which wipe against each other asthey are plugged and unplugged, thereby cleaning the connectors.However, the wiping action also limits the ability to unplug and replugthe connectors, often to 10-15 times, thereby preventing their use forportable cartridges. U.S. Pat. No. 5,970,030 shows that data storagedrives may be exchanged, employing low insertion force connectors whichrequire a complex connect/disconnect mechanism. Such connectors are notpractical for portable cartridges.

SUMMARY OF THE INVENTION

[0006] Hence, an object of the present invention is to provide anelectrical connection allowing direct data transfer to portablecartridges.

[0007] Another object of the present invention is to provide anelectrical connection which is releasable, and which connection isrepeatable.

[0008] A transfer station is provided for releasably, repeatablyelectrically coupling with respect to a portable cartridge. A substrateis mounted in the portable cartridge, the substrate having a pluralityof electrical contacts on a facing surface thereof, and the portablecartridge is capable of being engaged by a loader. In the transferstation, a matching circuitized flexible substrate is provided havingelectrical contacts on a facing surface thereof, the electrical contactsarranged to match the portable cartridge electrical contacts when in aface-to-face relationship. An elastomeric compression element, which hasa plurality of protruding compression members, is positioned at a rearsurface of the matching circuitized flexible substrate with theprotruding compression members facing and in contact with the rearsurface, such that individual compression members are registered withcorresponding individual electrical contacts. Elongated electricalcontacts are registered with two adjacent individual compressionmembers. A reference plate supports the elastomeric compression element.A loader engages the portable cartridge, registering the cartridgesubstrate electrical contacts in face-to-face relation with the matchingcircuitized flexible substrate electrical contacts, and exerting a forceon the portable cartridge normal to the facing surface of the matchingcircuitized flexible substrate. The normal force causes the portablecartridge substrate to compress the elastomeric compression elementbetween the matching circuitized flexible substrate and the referenceplate to create non-wiping contact between the electrical contacts ofthe portable cartridge substrate and the electrical contacts of thematching circuitized flexible substrate, thereby forming a releasable,repeatable electrical connection therebetween.

[0009] A portable cartridge is provided for mating with a transferstation having a data transfer interface with electrical contacts on acompression element and having a cartridge loader. The cartridgecomprises a data handling agent, such as an encased, self-contained,magnetic data storage drive. In accordance with the present invention,the cartridge comprises a substantially flat substrate having electricalcontacts on a facing surface thereof, the electrical contacts arrangedto match the transfer station data transfer interface electricalcontacts when in a face-to-face relationship. The substantially flatsubstrate is coupled to the data handling agent. A cartridge shellsupports the data handling agent and the substantially flat substrate.The cartridge shell has at least one engagement surface, such as notchesand alignment holes, for engagement by the cartridge loader in thetransfer station, whereby the cartridge loader may engage the cartridge,register the cartridge electrical contacts in face-to-face relation withthe transfer station data transfer interface electrical contacts, andexert a force on the cartridge normal to the facing surface of thetransfer station data transfer interface to cause the portable cartridgesubstrate to compress the compression element to create non-wipingcontact between the electrical contacts of the portable cartridgesubstrate and the transfer station data transfer interface facingsurface, and forming a releasable, repeatable electrical connectiontherebetween.

[0010] For a fuller understanding of the present invention, referenceshould be made to the following detailed description taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is an isometric view of a portable data storage cartridgecontaining a data storage device in accordance with the presentinventions;

[0012]FIG. 2 is an exploded view of an example of a portable datastorage cartridge of FIG. 1 containing an encased magnetic data storagedrive;

[0013]FIG. 3 is a plan view of the portable data storage cartridge ofFIG. 2;

[0014]FIG. 4 is a plan view illustration of a flex cable of the portabledata storage cartridge of FIG. 2;

[0015]FIGS. 5A and 5B are respective top and cross-section views of abacking plate of the portable data storage cartridge of FIG. 2;

[0016]FIG. 6 is an isometric view of the bottom half of the cartridgeshell of FIG. 2, with the backing plate of FIGS. 5A and 5B;

[0017]FIG. 7 is a partially cut away isometric view of the portable datastorage cartridge of FIG. 2 illustrating the flex cable of FIG. 4;

[0018]FIG. 8 is an isometric view of an automated data storage libraryfor storing, transporting, and providing data transfer with respect toportable data storage cartridges of FIG. 1;

[0019]FIG. 9 is an isometric view of a transfer station for providingdata transfer with respect to the portable data storage cartridge ofFIG. 1 and for differentiating the portable data storage cartridge ofFIG. 1 from a tape cartridge;

[0020]FIG. 10 is an alternative isometric view of the transfer stationof FIG. 9, with a loaded portable data storage cartridge of FIG. 1;

[0021]FIGS. 11A and 11A are top view illustrations of an optical sourcemounted on a top plate of the transfer station of FIG. 10 for detecting,respectively, the portable data storage cartridge of FIG. 1 and a tapecartridge;

[0022]FIG. 12 is a plan view illustration of an example of a PCBmounting optical receivers for sensing the optical sources of FIGS. 11Aand 11B;

[0023]FIG. 13 is an isometric illustration of a compression member,reference plate, support member and clamps of the transfer station ofFIG. 9;

[0024]FIG. 14 is a plan view illustration of a flex cable of thetransfer station of FIG. 9;

[0025]FIG. 15 is a cross section illustration of compression member,reference plate, support member and clamps of FIG. 13, with the flexcable of FIG. 14;

[0026]FIG. 16 is a circuit diagram illustrating an electrostaticdischarge (ESD) path of the transfer station of FIG. 9 and of a portabledata storage cartridge of FIG. 1;

[0027]FIG. 17 is a side view cut away illustration of the transferstation of FIG. 9 illustrating the loading mechanism in an unloadedposition;

[0028]FIG. 18 is a cut away illustration of the transfer station of FIG.9 and of a portable data storage cartridge of FIG. 1 with the loadingmechanism in an unloaded position;

[0029]FIG. 19 is a side view cut away illustration of the transferstation of FIG. 9 illustrating the loading mechanism in a loadedposition;

[0030]FIG. 20 is a cut away illustration of the transfer station of FIG.9 and of a portable data storage cartridge of FIG. 1 with the loadingmechanism in a loaded position;

[0031]FIG. 21 is a circuit diagram illustrating a power transferinterface of the transfer station of FIG. 9 and of a portable datastorage cartridge of FIG. 1;

[0032]FIG. 22 is a diagrammatic illustration of a portable data storagecartridge of FIG. 1 containing a non-volatile solid state memoryassembly; and

[0033]FIG. 23 is a diagrammatic illustration of a portable data storagecartridge of FIG. 1 containing an optical disk drive assembly.

DETAILED DESCRIPTION OF THE INVENTION

[0034] This invention is described in preferred embodiments in thefollowing description with reference to the Figures, in which likenumbers represent the same or similar elements. While this invention isdescribed in terms of the best mode for achieving this invention'sobjectives, it will be appreciated by those skilled in the art thatvariations may be accomplished in view of these teachings withoutdeviating from the spirit or scope of the invention.

[0035] Referring to FIG. 1, a data storage cartridge 40 is providedhaving a cartridge shell 41 comprising a substantially identicalexterior dimensional form factor as a tape cartridge with its leaderblock. The data storage cartridge comprises a blocking portion 42 todifferentiate identification of the data storage cartridge 40 from atape cartridge. In one aspect, the blocking portion 42 is opaque tooptically block an optical source from a corresponding sensor, whereasthe prior art leader block hole will transmit an optical beam, therebydifferentiating the data storage cartridge 40 from a tape cartridge.Alternatively, or additionally, an opaque blocking portion 43 may belocated on the opposite side of the data storage cartridge 40. Inanother aspect, a blocking portion 44 is located at a side of thelocation of the leader block hole at which the threading pin of a tapedrive begins engagement of a tape cartridge, and thereby preventsengagement of the data storage cartridge and provides differentiatedidentification of the portable data storage cartridge.

[0036] A notch 45, similar to the notch of a tape cartridge, is providedto interlock with a holder in a storage shelf of an automated datastorage library which tends to hold the data storage cartridge inposition in the shelf.

[0037] As will be discussed, the cartridge shell 41 mounts a datahandling agent, such as a data storage device, therein. Also as will bediscussed, an external data transfer interface electrical connector 48is provided, incorporating a substrate 50, having electrical contacts 51on a facing surface of the substrate. The electrical contacts 51 arecoupled to the data handling agent, and are arranged to match electricalcontacts of a transfer station, when in a face-to-face relationship.

[0038] Alignment, or registration, holes 55 and 56 are provided and matewith corresponding alignment pins of the transfer station to laterallyalign and register the data transfer interface of the portable cartridge40 with a data transfer interface of the transfer station.

[0039] An exploded view of an example of a portable data storagecartridge 40 of FIG. 1 is illustrated in FIG. 2, and a plan view isillustrated in FIG. 3, and contains an encased, self-contained andoperational magnetic data storage drive 60. An example of an encased,self contained, magnetic data storage drive of the desired form factorto fit within the cartridge shell 41 comprises the IBM Travelstar 2.5inch series of magnetic data storage drives. Specifically, FIGS. 2 and 3illustrate the bottom half 46 of the cartridge shell 41.

[0040] Referring to FIGS. 1-3, in one aspect, notches 58 and 59 areprovided to allow a loader of the transfer station to engage theportable data storage cartridge 40 and to force the electrical contacts51 of the data transfer interface electrical connector 48 intonon-wiping contact with matching electrical contacts of the transferstation.

[0041] In another aspect, a shock mount 62 supports and mounts the datastorage device within the cartridge shell 41. Specifically, FIGS. 2 and3 illustrate the bottom half 63 of the shock mount 62. The shock mount62 is arranged to insure that the data storage device is fully separatedfrom and isolated from potential mechanical contact with the cartridgeshell or the data transfer interface electrical connector 48. Referringadditionally to. FIG. 4, a flex cable 65 both provides the electricalcontacts 51 at a substrate 71 and interconnects the data storage deviceand the external data transfer interface 48, while also isolatingmechanical contact between the data storage device and the cartridgeshell 41, thereby further insuring the full separation and mechanicalisolation of the data storage device, such as the encased magnetic diskdrive assembly 60, from the cartridge shell 41. As the result, the datastorage device is protected from rough handling and is able to withstandthe dropping of the cartridge, or misplacement the cartridge such thatit is handled roughly, either through actions of a robot accessor orthrough manual handling.

[0042] With respect to this aspect of the present invention, thecartridge shell 41, shock mount 62, data transfer interface 48, and flexcable 65 may comprise any configuration suitable for supporting aparticular data storage device, while isolating mechanical contactbetween the data storage device and the cartridge shell. Specifically,the cartridge shell 41 may comprise an exterior dimensional form factordiffering from that of a tape cartridge with a leader block.

[0043] The data storage device 60 is preferably encased, self-containedand operational, comprising both the necessary mechanical and electroniccomponents. In the context of an encased magnetic disk drive assembly,the assembly comprises at least one rotatable disk, a motor for rotatingthe disk(s), at least one head, an actuator and servo system for seekingand tracking, and addressing, motor control, and data handlingelectronics for reading and writing data, and for communicating at thedata transfer interface, for example, employing an industry standardformat, such as IDE, SCSI or PCI. Thus, the device does not have to beopened to provide data transfer.

[0044] Referring additionally to FIGS. 5A, 5B, 6 and 7, a substantiallyflat backing plate 70 is provided which supports and mounts atermination 71 of the flex cable 65 of FIG. 4, forming the electricalconnector 48. The backing plate 70 and flex cable termination 71 snapinto slots 73 and 74 in the cartridge shell 41 for mechanical support.The backing plate 70 thus supports and positions the facing surface 50of the flex cable 65 to form the external data transfer interfaceelectrical connector. FIG. 7 also illustrates the top half 72 of theshock mount 62 and the top half 75 of the cartridge shell 41.

[0045] The flex cable 65 comprises a plurality of lands coupled to theelectrical contacts 51 of the facing surface 50 at the termination 71,and are coupled to the data storage device, such as encased magneticdata storage drive 60, for example, at a connector 76 at the rear toprovide the above described mechanical isolation.

[0046] In one embodiment, the electrical contacts 51 of thesubstantially flat substrate facing surface 50 comprise pads containinggold for providing gold contact surfaces. For example, the contactscomprise copper pads on which are plated a diffusion barrier, such asnickel, and Type II gold pads plated on the diffusion barrier, but whichare plated to-a thickness greater than standard. As an example, thethickness of the gold pads is substantially 100 micro inches. As definedby those of skill in the art, a plating of about 8 micro inches isconsidered a “flash”, about 15 micro inches is considered “adequate”,and about 30 micro inches is considered “standard”. The diffusionbarrier is preferably plated to a thickness greater than 50 microinches. Type II gold pads are also referred to as “hard gold” by thoseof skill in the art, and comprises a defined set of alloys. Preferably,the gold pads are electrolytically plated.

[0047] In an alternative embodiment, other materials havingcharacteristics similar to gold may be employed for the electricalcontacts 51, such as palladium or palladium-nickel. Pads containingpalladium forming the electrical contacts may have a gold “flash” layer.

[0048] In a preferred embodiment, the electrical contacts 51 aresubstantially flat, having substantially flat contact surfaces on thepads. Electrical contact physics defines that the actual contact is madevia small microstructure high spots on the contact surface, referred toas “aspirates”, distributed throughout the contact interface, eventhough the contact surface is substantially flat.

[0049] As an alternative embodiment, the electrical contacts 51 maycomprise shaped contacts having shaped surfaces on the pads. In“Hertzian” theory, shaping the surfaces tends to concentrate contactforce in small contact area. The shaping may be achieved by plating ormaterial removal, and may assume various shapes, referred to as, e.g.,dimple, crowned, hertzian stress dot, flat on sphere, dendrite, crossedcylinders, sphere on cup, or sculptured.

[0050] Further, at least one of the electrical contacts 51 of thesubstantially flat substrate facing surface comprises an elongatedcontact, as will be discussed.

[0051] As illustrated by the cross section shown in FIG. 5B, the backingplate 70 is in the general form of an “H” beam, with a front portion 77supporting and positioning the flex cable termination 71, and a rearportion 78 which provides structural strength. As will be discussed, thedata storage cartridge 40, when loaded into the transfer station, willbe subjected to considerable force in a direction normal to the facingsurface 50, for example, over 10 pounds, to effect the non-wipingcontact with the transfer station data transfer interface, requiringthat the backing plate have considerable structural strength, forexample, comprising a hard, durable plastic. Examples of plastics havinggood structural strength comprise “Ryton”, a polyphenylene sulphideresin from Phillips 66; “Ultem”, a polyetherimide resin from GE, and“Lexan”, a polycarbonate from GE.

[0052] In another aspect, the alignment, or registration, holes 55 and56 are provided in the substantially flat backing plate 70 in closeproximity to the substantially flat substrate 50. The substrate 50 ofthe flex cable termination 71 is aligned with respect to the backingplate 70 at the time of assembly by use of a probe inserted throughholes 80 and 81 of the termination 71 and into holes 82 and 83,respectively, of the backing plate 70. Thus, the substantially flatsubstrate facing surface 50 is aligned with respect to the backing plate70 and the alignment or registration holes 55 and 56 therein. Thealignment holes are arranged for mating with corresponding transferstation alignment pins to register the external data transfer interfaceelectrical connector 48 with respect to the transfer station.

[0053] The flex cable 65, in addition to coupling with the data handlingagent, or data storage device, to provide data transfer with thecontacted transfer station, is coupled to a power input of the datahandling agent to provide power from the transfer station to the datahandling agent.

[0054] In another aspect, when registered and aligned with the transferstation, the backing plate 70 is in contact with the alignment pins atholes 55 and/or 56. The backing plate 70 comprises a semiconductiveplastic material having electrical resistivity. In one example, thematerial has sufficient embedded carbon to provide the electricalresistivity, comprising 10%-30% carbon filled plastic. As analternative, the backing plate 70 comprises two plates, one platecomprising the “H” beam, and the other plate, preferably in front of the“H” beam, and with the alignment holes, comprising a carbon filledsemiconductive member. The backing plate is electrically coupled to thedata storage device by means of land 85 of flex cable 65, to a groundthereof, thereby forming an electrostatic discharge path from the datastorage device to the backing plate and through the electricallysemiconductive material to the alignment pins of the transfer station,which are electrically grounded, as will be discussed. Any of the abovediscussed plastics may be carbon filled and employed as the backingplate 70 or as the carbon filled one of two plates. A specific exampleof a carbon filled plastic comprises a 20% carbon filled polycarbonate,called “Stat-Kon DC-1004-FR”.

[0055]FIG. 8 illustrates an automated data storage library 90 forstoring, transporting, and providing data transfer with respect to tapecartridges 10 and portable data storage cartridges 40 of FIG. 1. Thelibrary 90 comprises at least one, and preferably a plurality of, datastorage drives 92 for reading and/or writing data on data storage media,such as the tape cartridges 10. Additionally, the library comprises atleast one, and preferably a plurality of, transfer stations 93 forproviding data transfer with respect to the data storage cartridges 40.Both the tape cartridges 10 and the data storage cartridges 40 arestored in storage shelves 95. The various cartridges may be stored in asegregated manner or may be stored randomly throughout the storageshelves. A typical automated data storage library also comprises one ormore input/output stations 97 at which a cartridge may be received ordelivered. A robot accessor 98, including a gripper 99, grips andtransports a selected cartridge 10 or 40 amongst a storage shelf 95, aninput/output station 97, a transfer station 93 and/or a data storagedrive 92. The automated data storage library robot accessor may alsoinclude a media sensor 96. The media sensor 96 may comprise a labelreader, such as a bar code scanner, or a reading system, such as a smartcard or RF (radio frequency) reader, or other similar type of system,which is able to identify the cartridge, such as by means of its volumeserial number, or VOLSER. As one example, the VOLSER may comprise alabel placed on the cartridge which is read by a bar code reader. Asanother example, the VOLSER may be in recorded in an RF chip in thecartridge which is read by an RF receiver.

[0056]FIGS. 9-20 illustrate an embodiment of a transfer station 100 andvarious components. The transfer station may be employed on astand-alone basis, or may comprise a transfer station 93 of theautomated data storage library 90 of FIG. 8.

[0057] In one aspect, referring to FIGS. 9-12, the transfer station 100is arranged to provide data transfer with respect to portable datastorage cartridges 40 of FIG. 1, where the portable data storagecartridge has generally an exterior dimensional form factor of a tapecartridge 10 having a leader block. As discussed above, the leader blockcomprises a hole therethrough for engagement by a threading pin. Also asdiscussed above, the portable data storage cartridge 40 comprises ablocking portion, such as the blocking portion 42, of the cartridgeshell 41, which is opaque.

[0058] The transfer station 100 comprises a receiver 103 for receivingthe portable data storage cartridge. The cartridge may be receivedmanually, or may be received from the robot accessor of the automateddata storage library 90 of FIG. 8, or may be received from an automatedcartridge loader (ACL) as is known to those of skill in the art.

[0059] Optical sources 105 and 106 are mounted at openings 107 and 108of a top plate 109 of the transfer station. Sensors 115 and 116 aremounted on a printed circuit board (PCB) 118 for sensing the opticalsources 105 and 106, respectively. The optical sources 105 and 106preferably comprise an infrared source, such as an LED optical source,which is focused, providing a focused beam directed toward therespective sensor 115 and 116, which preferably comprise infraredoptical sensors.

[0060] Optical source 105 and corresponding sensor 115 are located neara receiving slot 120 of the transfer station into which the cartridge isinserted. Thus, as the cartridge, whether it is a tape cartridge 10 or aportable data storage cartridge 40, the cartridge interrupts the beam,such that the sensor 115 detects that a cartridge is being inserted intothe receiver 103. Stops 121 and 122 are provided at the end of travel ofreceiver 103, and comprise the point at which the cartridge is fullyreceived into the transfer station.

[0061] Optical source 106 is located at, and directed toward thelocation of the leader block hole 19 of a tape cartridge 10 and thelocation of the blocking portion 42 of a portable data storage cartridge40 when a cartridge is at the end of travel in the receiver. Thecorresponding sensor 116 is positioned at the location of the leaderblock hole and blocking portion at the opposite side of the cartridgefrom the optical source 116. The sensor 116 may be enabled by the sensor115, and senses the blockage of the optical source 106 by a cartridgeshell blocking portion, thereby identifying the differentiatedidentification of the data storage cartridge, and indicating thepresence of the portable data storage cartridge 40 at the end of travelin the receiver 103. Sensor 116 will therefore enable the transferstation to load the portable data storage cartridge 40. If the beam isnot blocked, such that sensor 116 continues to detect the beam from theoptical source 106, either the cartridge has not been fully insertedinto the receiver 103, or the cartridge is a tape cartridge 10, and thebeam is received through the leader block hole 19. In this situation,there is an error, and the transfer station will not proceed.

[0062] As is understood by those of skill in the art, one or both source105, 106 and corresponding sensor 115, 116 may be reversed, the sourcelocated on the PCB 118, and the sensor on the top plate 109. Also as isunderstood by those of skill in the art, alternative locationsintermediate the PCB and on the top plate may also be employed formounting the sources and sensors.

[0063] Referring to FIGS. 9 and 13-15, in another aspect, a datatransfer interface electrical connector 130 of the transfer station 100is illustrated for mating with the external data transfer interfaceelectrical connector 48 of the portable data storage cartridge 40, ofFIGS. 1-7. The transfer station 100 releasably, repeatably provides anelectrical coupling with respect to the cartridge external data transferinterface, which comprises a substrate 71 having a plurality ofsubstantially flat electrical contacts 51 on a substantially flat facingsurface 50 thereof, the substrate mounted in a portable cartridge 40capable of being engaged by a loader.

[0064] The electrical connector 430 comprises an elastomeric compressionelement 132 having a plurality of protruding compression members 133supported by a reference plate 134. Preferably, the compression elementis fixed to the reference plate 134. As examples, the compressionelement may be cemented, bonded, or vulcanized to the reference plate.The compression element is positioned at a rear surface 135 of amatching circuitized flexible substrate 136, which preferably comprisesa termination of a flex cable 138. The matching circuitized flexiblesubstrate 136 has electrical contacts 141 on a facing surface 140thereof, the electrical contacts 141 arranged to match the portablecartridge electrical contacts 51 when in a face-to-face relationship.The protruding compression members 133 of the compression element 132are facing and in contact with the rear surface 135, such that theindividual compression members 133 are registered with the correspondingindividual electrical contacts 141.

[0065] The compression element 132 is generally of the type described inU.S. Pat. Nos. 4,902,234; 5,059,129; 5,873,740; or 5,947,750.

[0066] At least ones of the electrical contacts 141 of the matchingcircuitized flexible substrate 136 of flex cable 138, and correspondingones of the electrical contacts 51 of the substantially flat substratefacing surface 50 of the flex cable 65 of FIG. 4, comprise elongatedcontacts, the contacts 141 each registering with two adjacent individualcompression members 133 of the elastomeric compression element 132. Inthis manner, the elongated contacts comprise redundant contacts over twocompression members, and have matching contact surfaces which are atleast twice as great in surface area as a single contact of the size ofa single compression member.

[0067] Thus, in the electrical connector 130, the circuitized flexiblesubstrate 136 is positioned on the elastomeric compression element 132such that a rear surface of the substrate is in contact with thecompression members 133, and the elongated contacts 141 on the facingsurface 140 of the substrate are registered with two adjacent individualcompression members 133. Further, in the electrical connector 48, whenthe substrate 71 is registered in face-to-face relation with the facingsurface 140 of the mating electrical connector 130, the elongatedcontacts 51 are each positioned to overlie two adjacent individualcompression members 133, and with the elongated electrical contacts 51in releasable contact with corresponding elongated contacts 141.

[0068] The elongated contacts 51, 141 registering with two adjacentcompression members 133 provide redundant contacts with independentnormal force generation. Specifically, each adjacent compression memberprovides the contact normal force to a discrete region of the elongatedpad, and the ability of each region to make reliable contact can beconsidered independent and therefore redundant. For well designedelectrical contacts operating at an intrinsic failure rate (FR), theeffect of adding redundant contacts is to reduce the overall contactfailure rate. The effective failure rate (EFR) for multiple contacts inparallel can be estimated by dividing the failure rate (FR) by thenumber of contacts in parallel. Specifically, (EFR)=(FR)/(# of contactsin parallel). Thus, as shown by the equation, the additional of asecond, redundant contact reduces the effective failure rate of acontact by about ½.

[0069] The effect of redundant contacts on the plug dependent failurerate, or the ability of a contact to make electrical contact duringfirst plugging follows a similar equation. Therefore, two contacts inparallel provide a higher probability of successfully plugging anelectrical connector, and, hence, the data handling device.

[0070] As with respect to the electrical contacts 51 of flex cable 65 ofFIG. 4, the electrical contacts 141 of the substantially flat substratefacing surface 140 may comprise pads containing gold, and preferablycomprise copper pads on which are plated a diffusion barrier, such asnickel, and Type II, or “hard”, gold pads plated on the diffusionbarrier, but which are plated to a thickness greater than standard, forexample, to a thickness of substantially 100 micro inches. The diffusionbarrier is preferably plated to a thickness greater than 50 microinches. Preferably, the gold pads are electrolytically plated.

[0071] The electrical contacts 141 may also alternatively comprise othermaterials, such as pads containing palladium, such as palladium orpalladium-nickel, and may have a gold “flash” layer.

[0072] The electrical contacts 141 preferably are substantially flat,having substantially flat contact surfaces on the pads. Alternatively,the electrical contacts 141 may comprise shaped contacts having shapedsurfaces on the pads, as discussed above.

[0073] The flex cable 138 comprises a plurality of lands coupled to theelectrical contacts 141 of the facing surface 140 at the termination136, and are coupled to the PCB 118 of FIG. 12 at connector 145 attermination 146 of the flex cable.

[0074] In another aspect, alignment, or registration, holes 155 and 156are provided in close proximity to the electrical contacts 141. The flexcable termination 136 is aligned and the electrical contacts 141registered with respect to the compression members 133 at the time ofassembly by use of a probe inserted through holes 157 and 158 of thetermination 136 and into holes 155 and 156, respectively, and the flexcable termination is tightened to a predetermined amount at thecompression members. As will be discussed, the matching circuitizedflexible substrate 136 is tightened only sufficiently to attainregistration, while issuing from the elastomeric compression element 132without an immediate change in direction, and subsequently forming agradual curve 160, 161 in a direction normal to the facing surface 140.Then, clamps 162 and 163 are bolted into place to hold the circuitizedflexible substrate in place. In the illustrated example, clamp 162 holdsthe flex cable at tail 164, and clamp 163 holds the flex cable 138. Aswill be discussed, when the external interface of the portable datastorage cartridge is registered with the matching circuitized flexiblesubstrate electrical contacts 141, a loader exerts a force on theportable cartridge normal to the facing surface 140, compressing theelastomeric compression element 132 between the matching circuitizedflexible substrate 136 and the reference plate 134. The arrangement ofthe matching circuitized flexible substrate 136 to issue from theelastomeric compression element 132 without an immediate change indirection and subsequently form the gradual curve 160, 161 in adirection normal to the facing surface 140, allows the substrate to movefreely in the normal direction without pulling in the lateral direction.This creates a non-wiping contact between the electrical contacts 51 ofthe portable cartridge substrate 50 of FIG. 1 and the electricalcontacts 141 of the matching circuitized flexible substrate 136, therebyforming a releasable, repeatable electrical connection therebetween.

[0075] In another aspect, referring additionally to FIG. 18, thetransfer station 100 additionally comprises alignment pins 165 and 166for mating with respective registration holes 55 and 56 of the portabledata storage cartridge 40 of FIG. 1 to register the external datatransfer interface electrical connector 48 with the station datatransfer electrical connector interface 130. Both alignment pins arealigned substantially normal to the facing surface 140 of the matchingcircuitized flexible substrate 136, and are tapered at the ends 167 and168, respectively, to a rounded point in the direction of the portablecartridge substrate 50 to orient the portable cartridge substrate andgradually laterally align the portable cartridge substrate and thematching circuitized flexible substrate 136. To prevent tolerancebuildup between the alignment pins and the respective registrationholes, alignment pin 165 is preferably cylindrical, the same as thecorresponding registration hole 55, and of a slightly lesser diameter.As an example, the alignment pin may have a diameter 5% less than thatof the registration hole. However, alignment pin 166 is instead anon-round pin, such as a “diamond” pin, as is known to those of skill inthe art, and is substantially narrower than pin 165, but of the sameheight. Thus, the external interface electrical connector 48 of theportable data storage cartridge 40 is properly registered in thevertical direction at both ends by the alignment pins and is properlyregistered in the horizontal direction by the alignment pin 165.

[0076] In another aspect, referring to FIGS. 15 and 20, the facingsurface 140 of the matching circuitized flexible substrate is orientedparallel to gravity, and the cartridge loader is oriented to provide the“normal” force orthogonal to gravity, to minimize debris deposition onthe facing surface 140.

[0077] In another aspect, and additionally referring to FIG. 16, whenregistered and aligned with the transfer station, the backing plate 70of the portable data storage cartridge 40 of FIGS. 6 and 7 is in contactwith the alignment pins 165 and 166 at registration holes 55 and/or 56.As discussed above, the backing plate 70, and therefore the registrationholes 55 and 56 are electrically coupled to the data storage device,such as magnetic data storage drive 60, by means of land 85 of the flexcable, to a ground thereof, thereby forming an electrostatic dischargepath from the data storage device to the backing plate and through theelectrically semiconductive material to the alignment pins. The datastorage device, since it is within a portable data storage cartridge, isnot externally grounded and, as such, comprises an electrostatic sourcein the cartridge. The alignment pins 165 and 166 are conductive andcoupled to a ground path 169, via support member 170, thereby forming anelectrostatic discharge path from the registration holes 55 and 56 ofthe portable data storage cartridge 40 to the ground path 169.

[0078] Referring to FIGS. 10 and 17-20, a loader of the transfer station100 is illustrated which loads the portable data storage cartridge,exerting a force normal to the facing surface 140 of the flex cable 138of FIG. 15. FIGS. 17 and 18 illustrate a cartridge 40 at the end oftravel in the receiver 103 at the stops (only stop 122 is shown), andbefore the cartridge is loaded. FIGS. 10, 19 and 20 illustrate acartridge that has been loaded. FIG. 20 also illustrates the flex cable138 as arranged to loop over and outside the mechanism of the transferstation 100 to the PCB 118, thereby both allowing ease of assembly andof replacement of both the PCB and the flex cable.

[0079] The loading mechanism is initially at an “insert” position withmotor 180 having operated through gear train 181 to rotate bell crank182 toward the front of the transfer station 100. Bell crank 182 hasthus pushed beam 184 toward the front of the transfer station, whichpushed arm 185 of receiver 103, and therefore the receiver 103 towardsthe front opening 120 of the transfer station. Guides 186 and 187 of thearm 185 ride in slots. 188 and 189 of the transfer station and movablysupport the receiver 103 as it moves forward and backwards. Anengagement arm 190 is attached to the receiver 103 at pivot 191, andincludes a guide 192 which moves in slot 195 of the transfer station. Asis understood by those of skill in the art, the guides, arms, beams andslots are the same on each side of the receiver 103. Also as isunderstood by those of skill in the art, differing arrangements ofguides, arms, beams and slots may be employed in accordance with thepresent invention.

[0080] When the receiver 103 is in the “insert” position toward thefront opening 120 of the transfer station, slot 195 pulls guide 192down, away from the receiver 103. An engagement pin 200 is located onthe same shaft as guide 192, on the opposite side of arm 190, andprotrudes toward the interior of the receiver 103. Thus, as the guide192 is pulled down by slot 195, the engagement pin 200 is also pulleddown, out of the interior of the receiver 103. This allows a portabledata storage cartridge to be inserted into the receiver.

[0081] The loader is enabled by the sensor 116 of FIG. 12, which, asdiscussed above, identifies the differentiated identification of thedata storage cartridge, indicating the presence of the portable datastorage cartridge 40 at the end of travel in the receiver 103.

[0082] The sensor 116 enables motor 180 to operate through gear train181 to rotate bell crank 182 away from the front, and toward the rear,of the transfer station 100. Bell crank 182 thus pulls beam 184 towardthe rear of the transfer station, which pulls arm 185 of receiver 103,and therefore the receiver 103, towards the rear of the transferstation. As the receiver 103 is pulled toward the rear of the transferstation, slot 195 elevates guide 192 up, toward the receiver 103, suchthat engagement pin 200 is elevated into the receiver 103, where itengages the portable cartridge 40 of FIG. 1 at notches 58 and 59. As thereceiver continues to be pulled toward the rear of the transfer station,the engagement pins 200 exert a force on the portable cartridge 40normal to the facing surface 140 of the matching circuitized flexiblesubstrate 136. First, the alignment pins 165 and 166 engagecorresponding holes 55 and 56 of the cartridge to orient the portablecartridge substrate and gradually laterally align the portable cartridgesubstrate and the matching circuitized flexible substrate 136,registering the cartridge substrate electrical contacts 51 inface-to-face relation with the matching circuitized flexible substrateelectrical contacts 141. Then the engagement pins exert the normal forceon the portable cartridge and cause the portable cartridge substrate 50(and backing plate 70) to compress the elastomeric compression element132 between the matching circuitized flexible substrate 136 andreference plate 134 to create non-wiping contact between the electricalcontacts 51 of the portable cartridge substrate 50 and the electricalcontacts 141 of the matching circuitized flexible substrate 136, therebyforming a releasable, repeatable electrical connection therebetween.

[0083] As an example, the force generated by the loader may comprise atleast 30 grams per compression member, for a total normal force greaterthan 10 pounds on the cartridge, and compresses the compression elementa depth of about 0.022 inches. In loading the cartridge, the motor 180rotates bell crank 182 beyond the center of rotation to a stop, at anover-center position, so that the arm tends to be locked in position toprevent inadvertent release of the cartridge. The motor releases thecartridge by rotating back over center and then towards the frontopening 120 of the transfer station. Referring to FIGS. 19 and 20, inone embodiment, bell crank 182 is rotated beyond the center of rotationto a stop 193. In an alternative embodiment, bell crank 182 is rotateduntil beam 184 contacts the pivot end of bell crank 182, such that beam184 becomes a stop. When against the stop, the bell crank 182 is lockedunder pressure, providing the normal force to compress the compressionelement 132.

[0084] Referring-to FIGS. 13 and 18, ribs 202 and 203 are provided atthe edges of the compression element 132 to lightly clamp the flex cablesubstrate 136 of FIG. 14 to help restrain any lateral movement of theflex cable substrate as the individual compression members arecompressed under the contacts 141 of the interface.

[0085] Surface 171 and 172 straddle the flex cable substrate 136 andbutt up to the “H” beam 70 of the cartridge of FIG. 6 or the interface48 of the cartridge of FIG. 1, and limit the compression of thecompression members along the outer rows as the motor 180 of FIG. 10rotates bell crank 182 to the loaded position.

[0086] In another aspect, additionally referring to FIG. 21, theexternal data transfer interface electrical connector 48 of the portabledata storage cartridge 40, in addition to coupling with the datahandling agent, or data storage device, such as magnetic data storagedrive 60, to provide data transfer with the contacted transfer station100, comprises a power transfer interface coupled by one or more lands209 of the flex cable to a power input 210 of the data handling agent totransfer power from the transfer station 100 to the data handling agent.

[0087] In a further aspect, the power transfer interface additionallyboth verifies electrical contact between the data handling agent and thetransfer station before supplying full power, and when applying power,gradually ramps the application of power.

[0088] Specifically, a transfer station power supply provides power atinput 220 for the cartridge 40. A trickle circuit 222 limits currentflow to output 215, and to the data handling agent when electricalcontact is first made between contacts 141 of the transfer station 100and contacts 51 of the cartridge 40. Before contact is made, no currentflows, and output 215 is at the same voltage as power input 220, whichvoltage is detected by a detector 228. As soon as contact is made, asmall current flows to the data handling agent and back to ground 221,limited by the trickle circuit 222, reducing the voltage at output 215,detected by detector 228. Thus, detector 228 detects the current flow tothe cartridge 40, thereby verifying electrical contact between the datahandling agent and the transfer station.

[0089] Once electrical contact is verified, the detector 228 enablesramping circuit 230 to initially operate gate 233 to gate a small amountof power to output 215, and then gradually ramping gate 233 to ramp upto full power. As the power is ramped up, the voltage at output 215 isincreased, and may be detected by detector 228. Thus, optionally,detector 228 may be employed to detect any problems during applicationof full power evidenced by a change in voltage at output 215, andoperate ramping circuit 230 to open gate 233. An example of gate 233 isan FET. Detector 128 also detects “unmating”, or release of thecartridge 40 when the electrical contact is unmade, and operates rampingcircuit 230 to open gate 233. A fusing circuit 234 may be employed tolimit,transfer of excessive power to the cartridge 40. The electricalcontact verification and the gradual ramping of power insure that theactive data handling element or data storage device in the cartridge 40is protected from electrical spikes which could otherwise damage thedevice.

[0090]FIGS. 22 and 23 illustrate portable data storage cartridgescontaining alternative data handling or data storage devices. FIG. 22illustrates a portable data storage cartridge 40 of FIG. 1 containing anon-volatile solid state memory assembly 240. The solid state memoryassembly may advantageously comprise an “off the shelf” device, such asare readily available. FIG. 23 illustrates a portable data storagecartridge of FIG. 1 containing an optical disk drive assembly 250.Currently, commercially available opticals disk drives would have to bemodified to employ a non-removable optical disk. Other data handlingdevices may occur to those of skill in the art.

[0091] While the preferred embodiments of the present invention havebeen illustrated in detail, it should be apparent that modifications andadaptations to those embodiments may occur to one skilled in-the artwithout departing from the scope of the present invention as set forthin the following claims.

We claim: 1-56. (Canceled)
 57. An automated data storage library,comprising: storage shelves for storing portable data storagecartridges; at least one robot accessor having a gripper, said robotaccessor for gripping and transporting at least one selected saidportable data storage cartridge with respect to said storage shelves;and a transfer station for releasably, repeatably electrically couplingwith respect to a substrate having a plurality of electrical contacts ona substantially flat facing surface thereof, said substrate mounted insaid portable data storage cartridge capable of being engaged by aloader, comprising: a matching circuitized flexible substrate havingelectrical contacts on a facing surface thereof, said electricalcontacts arranged to match said portable cartridge electrical contactswhen in a face-to-face relationship; an elastomeric compression elementhaving a plurality of protruding compression members positioned at arear surface of said matching circuitized flexible substrate and saidprotruding compression members facing and in contact with said rearsurface, individual said compression members registered withcorresponding individual said electrical contacts; a reference plate forsupporting said elastomeric compression element; and a loader forengaging said portable data storage cartridge as received from saidrobot accessor, registering said cartridge substrate electrical contactsin face-to-face relation with said matching circuitized flexiblesubstrate electrical contacts, and exerting a force on said portablecartridge toward said facing surface of said matching circuitizedflexible substrate to cause said portable cartridge substrate tocompress said elastomeric compression element between said matchingcircuitized flexible substrate and said reference plate to createnon-wiping contact between said electrical contacts of said portablecartridge substrate and said electrical contacts of said matchingcircuitized flexible substrate, thereby forming a releasable, repeatableelectrical connection therebetween.
 58. The automated data storagelibrary of claim 57, wherein said electrical contacts of said transferstation matching circuitized flexible substrate comprise pads containinggold.
 59. The automated data storage library of claim 58, wherein saidtransfer station matching circuitized flexible substrate comprisescopper pads on which are plated a diffusion barrier, and Type II goldpads plated on said diffusion barrier.
 60. The automated data storagelibrary of claim 59, wherein said transfer station gold pads are platedto a thickness greater than standard.
 61. The automated data storagelibrary of claim 57, wherein said electrical contacts of said transferstation matching circuitized flexible substrate comprise pads containingpalladium.
 62. The automated data storage library of claim 57, whereinsaid transfer station loader is arranged to provide said force on saidportable cartridge toward said facing surface of said matchingcircuitized flexible substrate, as a force normal to said facing surfaceof said matching circuitized flexible substrate.
 63. The automated datastorage library of claim 62, wherein said transfer station loader isarranged to provide said normal force in the amount of at least 30 gramsper individual compression member.
 64. The automated data storagelibrary of claim 57, wherein at least ones of said electrical contactsof said transfer station matching circuitized flexible substratecomprise elongated contacts, each registering with two adjacent saidindividual compression members of said elastomeric compression element.65. The automated data storage library of claim 57, wherein saidtransfer station reference plate is substantially flat, providingsubstantially uniform support of said elastomeric compression element.66. The automated data storage library of claim 57, wherein saidtransfer station additionally comprises alignment pins in closeproximity to said elastomeric compression element, said alignment pinsaligned substantially normal to said facing surface of said matchingcircuitized flexible substrate for mating with corresponding alignmentholes of said portable cartridge to laterally align said portablecartridge substrate and said matching circuitized flexible substrate.67. The automated data storage library of claim 66, wherein saidtransfer station alignment pins are tapered to a rounded point in thedirection of said portable cartridge substrate to orient said portablecartridge substrate and gradually laterally align said portablecartridge substrate and said matching circuitized flexible substrate.68. The automated data storage library of claim 66, wherein saidtransfer station alignment pins extend beyond said matching circuitizedflexible substrate a distance sufficient to contact a cartridge failingto have said alignment holes, to protect said matching circuitizedflexible substrate from contact with said cartridge.
 69. The automateddata storage library of claim 66, wherein said transfer stationalignment pins are conductive and coupled to ground to discharge anyelectrostatic charge at said corresponding alignment holes of saidportable cartridge.
 70. The automated data storage library of claim 57,wherein said transfer station facing surface of said matchingcircuitized flexible substrate is oriented parallel to gravity, and saidtransfer station loader is oriented to provide said force orthogonal togravity, to minimize debris deposition on said facing surface.
 71. Theautomated data storage library of claim 57, wherein said transferstation matching circuitized flexible substrate comprises a terminationof a flex cable.
 72. The automated data storage library of claim 71,wherein said transfer station flex cable issues from said elastomericcompression element without an immediate change in direction, andsubsequently forming a gradual curve in said normal direction tomaintain symmetrical force on said matching circuitized flexiblesubstrate as said elastomeric compression element is compressed.
 73. Theautomated data storage library of claim 57, wherein said electricalcontacts of said transfer station matching circuitized flexiblesubstrate are substantially flat.
 74. The automated data storage libraryof claim 57, wherein said electrical contacts of said transfer stationmatching circuitized flexible substrate comprise shaped contacts. 75.The automated data storage library of claim 57, wherein said transferstation loader comprises at least one bell crank which rotates to anover-center position, thereby exerting said force on said portablecartridge.